Use of printed circuit board, electronic component, and semi-conductor assembly equipment for the assembly of razors and components thereof

ABSTRACT

The invention discloses a novel application of standard printed circuit board (PCB) assembly modules, electronic assembly, and/or semiconductor assembly equipment for the assembly of consumer products, such as razor cartridges. In addition, nozzles of the pick/place component placement machine of the present invention may be desirably adapted to operate on type of razor cartridge component (e.g., blade, lubricating strip) disposed on a pallet. The adapted nozzle may include adaptors which may have an elongated portion, an angled portion, a tapered portion, a gripper portion, a curved portion, a rounded portion, a pointed tip, a stamper, a marker, a printer, a guide portion, a spring portion, a moveable leg, or any combination thereof, for operating on a razor cartridge component.

FIELD OF THE INVENTION

This invention relates to razor cartridges, and more particularly to themanufacturing of consumer products such as razors and razor cartridges.

BACKGROUND OF THE INVENTION

In current manufacturing processes, wet shaving or razor cartridges aregenerally assembled on production lines dedicated to a particular typeof razor cartridge. Some known assembly machine layouts include machineswhich are synchronous, non-synchronous, or continuous which may havein-line indexing, dial (e.g., rotary) or carousel capabilities.

On these types of production lines, in-process cartridges aretransported, either by indexing or continuous motion, to the dedicatedassembly stations such as stations 12 and 14 shown in FIG. 1 andstations 14 and 16 in a known dial or rotary based assembly machinelayout 18 shown in FIG. 1A. For instance, dedicated assembly station 12(and similarly station 14) generally handles only one type of component,the same component (e.g., a cap) over and over again, while dedicatedassembly station 14 (and similar station 16) generally will handle onlyone type of component (e.g., a blade) over and over again. Thus, eachstation is designed to handle or deal with only one type of particularcomponent (e.g., a cap) and as such, is configured to grasp andsubsequently release only one type of component. At these stations,whether in an in-line or rotary production line of FIG. 1 or FIG. 1A,the components (e.g., a cap or a blade), required for the completion ofthe assembly of the cartridge, are added to the cartridge.

Thus, the operations of these types of production lines are generallysequential in nature (for intermittent, continuous, and asynchronousassembly methods), since a razor cartridge component moves along fromstation to station where each station performs a discrete operation(e.g., adding a cap to the cartridge housing) until a razor cartridge isformed.

These stations perform the assembly with custom, precision, and oftenunique tooling equipment such as cams and levers. Dedicated feed systemsF1, F2, F3, and F4 as shown in FIG. 1 and F5, F6, F7, F8, and F9 asshown in FIG. 2, may not only provide individual components to theassembly machine, but may also remove completed assemblies from themachine. Such feed systems may also oftentimes also require with custom,precision, and often unique tooling. These feed systems are generally“hard-connected” to the machine, in that they are connected bothmechanically and electrically. Thus, generally manufacturing processesof these assembly machine types are by their very nature typicallydesigned or dedicated to just one razor product family. That is, oneassembly machine is generally dedicated to making one type of product,(e.g., razor cartridge, razor handle, etc.) for one product family, forinstance the Gillette® Sensor® product family. This machine would not inturn be easily transferable to or capable of being used for any otherproduct family or families, such as the Gillette® Venus®, Gillette®Mach3®, or Gillette® Fusion® product families, nor vice-versa.

Thus, this type of process or design presents a major disadvantage withlimited flexibility for making changes in manufacturing, such as changesthat may be needed for producing cartridges for different productfamilies or changing the operation layout within the same assemblymachine and/or feed system.

For instance, if demand is low for one particular product family, buthigh for another, the low demand product's assembly machine may bedormant but because the dormant assembly machine is generally onlydedicated by design to handle one particular type of device or productfamily, it most probably could not be utilized to assist in producingthe high demand product.

Another disadvantage of this type of equipment is generally that thecost of capital may be very high, as every new product may necessarilyrequire its own customized and newly designed tooling, and the equipmentfor prior products may, in all likelihood, not be reusable for newproduct families.

One potential solution that may improve flexibility may be to programrobots (e.g., non-synchronous pallet based or stand-alone robots) ateach assembly station which may typically include vision driven systems.While robots may advantageously provide an increase in flexibility theymay be slower or have reduced precision over the known dedicatedassembly and feeding systems which are generally expeditiouslyoptimized, and they may come with a significant initial capital and costinvestment along with substantial upfront custom designing.

Thus, there is at least a need to improve the manufacturing processes toobtain more flexibility across product families.

SUMMARY OF THE INVENTION

The invention provides a razor cartridge assembly apparatus including apick/place component placement machine operating on at least one razorcartridge component. A nozzle on the pick/place component placementmachine is adapted depending on a type of said at least one razorcartridge component. The adaptor may include an elongated portion, anangled portion, a tapered portion, a gripper portion, a curved portion,a rounded portion, a pointed tip, a stamper, a marker, a printer, aguide portion, a spring portion, a moveable leg, or any combinationthereof, for operating on at least one razor cartridge component.

The operations performed on the razor cartridge component includecontacting, picking, placing, holding, snap fitting, articulatedinserting, angular inserting, cutting, assembling, clipping, crimping,staking, orienting, transporting, dispensing, inspecting, identifying,cold heading, marking, stamping, printing (e.g., laser or ink), etching,force placement (e.g., pushing, moving, sliding) or other physicalaction or part movement, or any combination thereof, at least one razorcartridge component, or at least one exterior surface of at least onerazor cartridge component. The operation of orienting includes rotating,pivoting, swiveling, spinning, revolving, tilting, turning, aiming,twisting, pointing, inclining, rolling, or any combination thereof.

The invention provides a method of utilizing a pick/place componentplacement machine including at least one nozzle, each nozzle operatingon at least one razor component.

The invention also provides an assembly apparatus including a pick/placecomponent placement machine where at least one nozzle is adapted tooperate on at least one consumer product component.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although methods and materialssimilar or equivalent to those described herein can be used in thepractice or testing of the present invention, suitable methods andmaterials are described below. All publications, patent applications,patents, and other references mentioned herein are incorporated byreference in their entirety. In case of conflict, the presentspecification, including definitions, will control. In addition, thematerials, methods, and examples are illustrative only and not intendedto be limiting.

Other features and advantages of the invention will be apparent from thefollowing detailed description, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which like designations are used todesignate substantially identical elements, and in which:

FIG. 1 is a schematic view of a prior art in-line assembly system for arazor cartridge.

FIG. 1A is a schematic view of a prior art rotary assembly system for arazor cartridge.

FIG. 2 is a schematic view of a various unassembled razor cartridgecomponents of the present invention.

FIG. 2A is a schematic view of additional razor cartridge components ofthe present invention.

FIG. 2B is a perspective view of a razor handle detached from anassembled razor cartridge.

FIG. 3 is a schematic view of a pick/place component placement machinefor a razor cartridge in accordance with the present invention.

FIG. 4 is a schematic view of a head portion of pick/place componentplacement machine in accordance with the present invention.

FIG. 5 is a flow diagram for the assembly of a razor cartridge inaccordance with the present invention.

FIGS. 6A through 6C are schematic views of alternate embodiments whereeach module has two heads.

FIG. 6D shows schematic views of alternate embodiments where each modulehas a single head.

FIGS. 7A and 7C are schematic views of alternate embodiments of thepresent invention with each module having four heads and FIG. 7B is aschematic view of an alternate embodiment of the present invention withone module having four heads arranged with another module having twoheads.

FIGS. 8-10 are schematic views of a nozzle having a novel adaptor foroperating on a razor component in accordance with the present invention.

FIGS. 11A and 11B depicts various adaptors or nozzle extension membersin accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

One novel area that has been not been developed in the prior art is theuse of standard printed circuit board (PCB) assembly modules, electronicassembly, and/or semiconductor assembly equipment, which have been up tonow used for other type of products or industries (e.g., computer orautomotive), for the assembly of consumer products, such as wet shavingor razor products and components thereof, such as razor cartridges.These standard printed circuit board (PCB) assembly modules, electronicassembly, and/or semiconductor assembly equipment machines are a majordeparture from current known manufacturing processes for razor productsdescribed in the Background of the Invention section, such as dedicatedassembly machines.

The term “standard modules” or “modules” or “pick/place componentplacement machine” as used in the present invention signifies thesetraditional printed circuit board (PCB) assembly equipment, electronicassembly equipment, and/or semiconductor assembly equipment. Manycompanies provide this type of equipment, such as Samsung, Europlacer,Sony, Juki, Panasonic, Fuji, Universal Instruments Corporation, Siemens,to name a few.

As will be described herein, in the present invention, these traditionalstandard modules are used as they are, and/or adapted, configured and/ortooled in such a way as to produce a viable production assembly line formanufacturing razor/shaving cartridges which may have differentrequirements than typically required of the standard modules of theprior art.

The PCB modules, electronic assembly, and/or semiconductor assemblyequipment of the present invention may desirably perform various razorcartridge assembly operations which may include, but would not belimited to, operations such as contacting, picking, placing, holding,snap fitting, articulated inserting, angular inserting, cutting,assembling, clipping, crimping, staking, orienting, transporting,dispensing, inspecting, identifying, cold heading, marking, stamping,printing (e.g., laser or ink), etching, force placement (e.g., pushing,moving, sliding) or other physical action or part movement, or anycombination thereof, as will be detailed below which may generally berequired for cartridge assembly.

The operation of orienting may desirably include movements such asrotating, pivoting, swiveling, spinning, revolving, tilting, turning,aiming, twisting, pointing, inclining, rolling, or any combinationthereof.

The term “razor cartridge component” and “razor component” as used inthe present invention signifies the components necessary for a specifictype of razor cartridge. Generally, as shown in FIG. 2, a razorcartridge 20 may desirably include at least one cap 26, (e.g., plasticcomponent or including a lubricating strip, liquid dispensing means,gels, or other chemistries, etc.) at least one guard 27, at least onerazor blade 22 (e.g., bent blade, blade with blade support or flatblade), at least one housing, frame or platform 24, at least one spacer(not shown), at least one trimmer 21, at least one trimmer frame 21 a,at least one clip 23, at least one cartridge connecting structure 28, atleast one overcap 25 a, dispenser 25 b, or dispenser container or tub 25c (shown in FIG. 2A), or any combinations thereof.

Other components of a razor cartridge may include an interconnect memberor a cartridge connecting structure 28 or other pivoting structure toconnect a cartridge to a handle. For the formation of a razor systemproduct, a razor handle 29 (as shown in FIG. 2B) and its variouscomponents comprised of elastomeric, metal, plastic, or coated plasticsmay also be included as components necessary in the final assembly. Assuch, depending on the type of razor cartridge or razor product to beassembled, the components to be utilized can be determined accordingly.In this way, the assembly and production of any component or device ispossible, from simple, single bladed cartridges to the most complextypes of cartridges. For other types of consumer products, such ascosmetic, medical or dental products, similar determinations for theirrespective components may be extrapolated from the present invention.

One major advantage of this novel application of standard modules is theavoidance of constructing new machines or custom, precision, and uniquemachine frames, structures, guarding, or chassis to perform assemblyoperations. This novel application thus has the advantage of reducingcapital build cost by benefiting from the economies of scale of adifferent industry and reduction of design and build time. In addition,a larger percentage of the machine has resale value to a larger audienceand can be sold on the open market without fear of losing trade secrets.

These advantages are made possible because generally PCB modules,electronic assembly, and/or semiconductor assembly equipment, innatelywork on the principle of having high speed, servo driven, Cartesiangantry, picking and placing multiple types of components generally withnozzles capable of handling multiple types of components or multipleproduct shapes via vacuum or suction, mechanical (e.g., grippers),electrical or magnetic means or any combination thereof.

The handling of razor components by standard PCB modules, electronicassembly, and/or semiconductor assembly equipment, may require noveland/or specialized modifications, interfaces or adaptors as will also bediscussed below.

Referring now to FIG. 3, an assembly machine or a pick/place componentplacement machine 30 including first module 32, second module 34, thirdmodule 36 and fourth module 38 is provided in accordance with thepresent invention. These modules perform the assembly operationsrequired to construct razor cartridges and may include PCB, electronicassembly and/or semiconductor assembly equipment of the prior art. Themodules may or may not be identical in structure or function.

The machine 30 has an input area 31 where the formation of a cartridgewill generally begin and an output area 39 where a razor cartridge 37will exit after assembly or a portion of the assembly is completed.

As cartridges are assembled, they may desirably be held on one or morepallets 35 which may travel through each module as the cartridges areprocessed. Pallets may be carriers, nests, trays or other transportdevices for cartridge components. The pallets may carry one or morecartridges. Each pallet 35 may desirably return to the beginning of theproduction line 40. Such a system may generally be referred to as a“recirculating carrier” or asynchronous pallet based system. Multiplepallets 35 may be conveyed on the production line 40.

Each module of the present invention may generally include at least onehead. As shown in FIG. 3, each module (first module 32, second module34, third module 36, and fourth module 38) is depicted having two headseach respectively, heads 32 a and 32 b for the first module 32, heads 34a and 34 b for the second module 34, heads 36 a and 36 b for the thirdmodule 36, and heads 38 a and 38 b for the fourth module 38.

Each head of each module may desirably have at least one nozzle mountedthereon. The nozzle may be mounted via mechanical means such as via aspindle (not shown) where the spindle connects the head with the nozzleand is capable of rotating. Standard PCB, electronic assembly and/orsemiconductor assembly equipment may have any number of nozzles disposedaround the head. For instance, some known systems may have 8, 12, 18,20, or up to 30 nozzles.

Thus, by having at least one head (each possibly having differentnozzles or “end effectors” as will be described below) associated witheach module, the arrangement of FIG. 3 provides increased flexibility infunctionality and the addition of heads per module, provides greaterthroughput in the assembly of razor cartridges over the prior art. Itshould also be noted that each nozzle may desirably be performing anoperation or combination of operations and as such, “paralleloperations” may be occurring. For example, one nozzle may be placing acomponent while a different nozzle may be orienting a component.

The modules are supplied with cartridge components by one or morestandard or custom feed systems, or any combination thereof, where eachfeed system is generally flexibly connected to a module via aninterface. Each module in FIG. 3 is depicted as desirably including twofeed systems; for instance, feed systems 33 a and 33 b for module 32,feed systems 33 c and 33 d for module 34, feed systems 33 e and 33 f formodule 36, and feed systems 33 g and 33 h for module 38. The feed system33 a generally serves a component type (e.g., housings) to head 32 a ofmodule 32 whereas feed system 33 b generally serves a differentcomponent type (e.g., guards) to head 32 b. Similarly, feed system 33 cserves head 34 a (e.g., blades) while feed system 33 d feeds head 34 bwith another type of component (e.g., lubricating strip), and so on.

Initially, pallets 35 may typically be empty with components beingplaced thereon subsequently via heads having been served by theirrespective feed system. This placement typically occurs in the center ofeach module or proximal to the module. Alternatively, pallets 35 mayinitially have components already, having been place thereon viaprocesses elsewhere. An empty pallet and a pallet with componentsalready thereon are shown in FIG. 3.

Generally, regardless if empty or not, the pallet 35 desirably serves asa carrier, carrying cartridge components in at least one area, depictedin FIG. 3 as a first area 35 a. Pallet 35 may be desirably conveyed ormove along on a type of conveyer belt or production line 40. The pallet35 may generally desirably travel to the center of each of the modules32, 34, 36, and 38 shown in FIG. 3 as it transports components along onproduction line or conveyor belt 40.

For instance, once the pallet 35 has moved to the center or in theproximal area of module 32, the heads 32 a and 32 b of module 32 maythen desirably interface with feed systems 33 a and 33 b of module 32 toobtain the required cartridge components and place them on an area ofthe pallet, such as first area 35 a.

Each module of the present invention may also generally work in a “batchprocess” mode. A batch process mode may be defined for purposes hereinas the capability to obtain and/or operate on more than one type ofcomponent to be processed. For instance, the heads may themselvesdesirably move or travel over to the first area 35 a where a supply ofparts or razor components are found (e.g., a part feeding area) andwhere it may pick up one or multiple parts to work with. These parts mayor may not be the same type. The head may then generally move to asecond area, the center of module 32 (e.g., the assembly area) where itmay desirably deliver or operate on one or multiple parts. There may bemultiple areas on a pallet used for either assembly or staging foradditional assembly work or manipulation. Cartridge components may bedelivered directly to the cartridge being assembled on pallet 35, or maybe transported to one or more separate areas 35 a or 35 b of the pallet35. A second area 35 b may be located on the same pallet 35 as shown inFIG. 3 or it may be located in an area on a different pallet 35′, 35″,etc. conveyed on line 40, or on a particular assembly location of theactual razor cartridge (e.g., end target placement) such as on a housingor frame 24.

In one scenario, head 32 a of first module 32 may be utilized to pick upmultiple cap components 26 (e.g., a lubricating strip component) whichare being carried on pallet 35 being conveyed on conveyer belt orproduction line 40 or the head 32 a may obtain these cap components viafeed system 33 a, pick up these cap components and then insert them ontoa specific area in a razor housing or frame 24 which may also be held onthe same pallet 35 or on a different proximal pallet. The second head 32b of first module 32 may be utilized to pick and place a differentcomponent (e.g., guard component 27) to be disposed in cartridge housingor frame 24 from feed system 33 b.

This partially assembled cartridge 37 a (e.g., housing 24 with guard 27and cap 26) may then be transferred via pallet 35 out of the firstmodule 32 to the second module 34 where heads 34 a and 34 b, interfacingwith feed systems 33 c and 33 d, are utilized to pick up one or moreadditional razor cartridge components (e.g., one or more blades 22) andplace these components onto the razor housing 24.

This process may desirably continue progressing through to thesubsequent modules 36 and 38 shown in FIG. 3 where different functionsoccur and until a complete razor cartridge 37 is finally formed. Finallyformed cartridge 37 may be unloaded at the end of the line 40 or passedonto a different machine (not shown) for further assembly (e.g.,attachment to a handle). In addition, the present invention contemplatesthat a head may desirably work effectively in reverse, in that itunloads finally formed or completed cartridges from pallets and deliversthem to the feed system to be transported elsewhere.

Alternatively, heads 32 a and 32 b and 34 a and 34 b of first and secondmodules 32 and 34 respectively may be configured to each pick upmultiple razor cartridge components of a different type. For instance,in lieu of head 32 a picking/placing cap components, it may beconfigured to pick/place any number of components, e.g., 5 housings, 10blades, 5 caps, etc., and in any combination thereof. This configurationmay be applied to any module arrangement.

In addition, multiple cartridges may be formed simultaneously using theprocesses described above. The batch processing mode of the modulesallows for potentially greater output rates theoretically as high asabout 100% to about 300% than possible if each module were working onindividual parts as in the prior art.

In addition, by having one or more nozzles mounted on the heads, as willbe described in more detail below, where the nozzles are desirablycapable of picking up and placing and performing operations describedherein on any number of the same type of parts, any number of differentparts, or any combination thereof, the flexibility of the presentinvention system is also substantially increased.

For instance, the switching or changing from assembling one type ofproduct to another different type of product, may, in accordance withthe present invention, generally be akin to a “push-button” or simplechange in some cases, whereas in the prior art, in order to change fromassembling one product type to a different product type, the prior artmachines would generally be “on hold” (e.g., not in use) anywhere fromseveral hours to potentially many months.

Thus, the present invention not only allows for increased customizationand the ability to balance equipment costs, sizes, and rates, but also,all the while providing the same assembly functionality and desirably ata higher output rate. Additionally, with the increase in flexibility,systems can be rapidly scaled up and rearranged or reconfigured.

Each of the heads 32 a, 32 b, 34 a, 34 b, 36 a, 36 b, 38 a, and 38 b maydesirably be somewhat robot-like, driven by a motor 45 and may generallyinclude an on-board vision system 46 (shown in FIG. 4). Such a visionsystem desirably assists in precision placement of components therebyreducing misalignment of components.

As discussed above, each head may desirably be able to “pick and place”similar or different types of components which together will form arazor cartridge. In a preferred embodiment, each head of the presentinvention may desirably comprise at least one nozzle or other toolcapable of picking up and placing down, among other operations (e.g.,cutting), at least one part (e.g., razor cartridge component). Forinstance, as shown in FIG. 4, head 32 a of FIG. 3 is depicted includingeight nozzles 42 mounted thereon.

In the present invention, at least one nozzle may be movable orrotatable about at least one axis where the at least one axis is an Xaxis, a Y axis, a Z axis, or any combination thereof. Furthermore, inthe present invention, at least one head may also be rotatable ormovable about at least one axis, where at least one axis is an X axis, aY axis, a Z axis, or any combination thereof. For instance, as shown inFIG. 4, head 32 a may generally rotate in a clockwise direction 44.

In addition, the present invention further contemplates that each headand each nozzle may each be rotatable or movable about any axissimultaneously. Generally, the nozzle and the head are moving above apallet, the latter which itself is also capable of movement about the Xaxis, Y axis, or Z axis, or any combination thereof.

For picking/placing razor components, the nozzles 42 shown in FIG. 4 maydesirably utilize vacuum or suction or gripper actuation mechanisms,though any feasible mechanical, electrical, chemical, magnetic mechanismor any combinations thereof, is contemplated in the present invention.

In addition to picking and placing components such as razor cartridgecomponents, the nozzles 42 may desirably perform other necessary typesof operations for assembling razor cartridges. Additional operations maydesirably include, but are not limited to, contacting, picking, placing,holding, snap fitting, articulated inserting, angular inserting,cutting, assembling, clipping, crimping, staking, orienting,transporting, dispensing, inspecting, identifying, cold heading,marking, stamping, printing (e.g., laser, ink), etching, force placement(e.g., pushing, moving, sliding) or other physical action or partmovement, or any combination thereof, The operation of orienting maydesirably include movements such as rotating, pivoting, swiveling,spinning, revolving, tilting, turning, aiming, twisting, pointing,inclining, rolling, or any combination thereof.

The head/nozzles of the modules may be adapted to dispense liquid orother chemistries into products, and may therefore be utilized toproduce cartridges that incorporate formulations, such as the typeutilized in the Venus Breeze gel bars and other liquid dispensing razorproduct families.

Accordingly, the present invention is capable of aptly balancingprocesses that may generally each require different takt times, (wheretakt time may generally be defined as the longest time spent on aparticular operation to meet the demand level and where typically anentire line may have a takt time), or have different processing rates,such as low speed solidification of chemistries or formulationsvis-à-vis high speed blade loading.

Furthermore, if components are supplied to modules (e.g., to the headsand/or nozzles) as strips of material (e.g., metal clip or lubricatingstrip material), the module, desirably via the nozzle or head of thepresent invention is thus capable of cutting, forming, and assemblingthe strips of material for placement into the appropriate cartridgelocation. A single clipping assembly has been demonstrated on similarmodules at forming, loading and crimping over 400 clips per minute.

In addition, any of the aforementioned operations (e.g., orienting,cutting, etc.) may take place in conjunction with, simultaneously with,or in spatial relation to another operation. For instance, a nozzle maypick up two different components and be capable of performing operationson each of the components at different heights (e.g., place onecomponent on top of the other or tilt one in relation to the other).

FIG. 4 also depicts a control unit 48 which may generally providequality control functionality, such as the ability to track at least onerazor component through the modules, to reject at least one razorcomponent for defectiveness or malfunction, to reject a final assembledrazor cartridge for defectiveness or malfunction, or any combinationthereof. The control unit 48 may also include a display and software orcomputer aided design tools affording improvements to inspection and/orrecognition of components before or after placement. Components that arefound to be defective may generally be disposed of in a scrap bin 48 a.The control unit 48 may be able to act “on the fly” if defectivecomponents are found and may also provide machine performance data andtrending analyses.

The vision system 46 may be adapted to facilitate at least one of theoperations of the nozzle (e.g., picking, holding, orienting,transporting and placing operations of the at least one razor component)and may generally include at least one camera 46 a. In general, thevision system assists the machine in deciding where to move, etc. Thecamera 46 a may be desirably configured to capture an image of at leastone nozzle, of at least one head, of at least one razor component, of atleast one razor cartridge component, partially assembled cartridge,completed cartridge, or any combination thereof. The vision system 46and camera 46 a may provide input 46′ to the control unit 48 to assistthe control unit in making quality determinations.

Advantageously, for instance, the control unit may desirably have theability to repair a component, a partially assembled cartridge, acompleted cartridge or any combination thereof, a feature not found inthe prior art dedicated assembly systems. For instance, if the controlunit determines a blade is missing from a partially assembled razorcartridge during assembly, the present invention machine may go back andobtain a blade to place in the razor cartridge, thereby repairing thecartridge, which in turn, reduces, scrap and may improve throughput,whereas in the prior art this cartridge would generally be scrapped ordisposed of.

Referring now to FIG. 5, a flow diagram depicting the basic flow of thepresent invention is shown. At the start step 51, pallet 35 (not shown)is assumed to have moved proximal to or under the center of one of themodules, such as first module 32. Right after the start 51, at step 52,the first head (e.g., head 32 a) of module 32 will generally load up itsnozzles 42 with a desired number and mix of cartridge components from afeed system (e.g., feed system 33 a). At step 54, head 32 a will performone or more operations on the razor cartridge components of the typedescribed above. One operation for instance may be to deliver thecomponent elsewhere or to orient it in a particular manner. The nozzlesof head 32 a will operate upon its required number of components untilcomplete. At this point, pallet 35, being still center to or proximal tomodule 32 may then be acted up by head 32 b of module 32 with steps 56and 58 similar to steps 52 and 54 described above in conjunction withhead 32 a. Once all operations are completed by the first module 32, thepallet 35 moves to be proximal to the second module 34 where the flow isrepeated for heads 34 a and 34 b of FIG. 3. This process then moves tothe third module 36 and so on until completion.

Although the steps for just one module of FIG. 3 and in essence onecartridge are effectively shown in FIG. 5, the number of cartridgesbeing processed may be variable which may dictate the number of loops inthe flow per module that occur. In addition, with multi-head machines,many of these operations may be occurring concurrently, and thus, theflow shown in FIG. 5 may be extrapolated in parallel.

FIGS. 6A and 6C depict alternate embodiments of FIG. 3 of the presentinvention where arrangements of modules 62 are shown each having twoheads 62 a and 62 b, and having feed systems 64 a, 64 b feeding acomponent type to head 62 a, feed systems 64 c, and 64 d feeding adifferent component type to head 62 b and feed systems 65 a, 65 bfeeding yet another component type to head 62 a and lastly feed systems65 c, and 65 d feeding still yet another different component type tohead 62 b of module 62.

FIG. 6B shows one module 62, two-headed machine 62 a and 62 b, each headhaving four feed systems 64 a, 64 b, 64 c, and 64 d and 65 a, 65 b, 65c, and 65 d, respectively, feeding heads 62 a and 62 b as describedabove with FIG. 6A.

In FIG. 6D, in accordance with three alternate embodiments of thepresent invention, single head machines are depicted in each module 62with two, three or four feed systems. For instance, single head 62 a inmodule 62 is shown having up to four feed systems 64 a, 64 b, 64 c, 64 dcapable of feeding or serving head 62 a. Any number of feed systemscapable of serving a single head is contemplated in the presentinvention.

FIGS. 7A through 7C depict schematic views of alternate embodiments ofthe present invention with each module 72 having at least four heads 72a, 72 b, 72 c, 72 d. FIG. 7B depicts an arrangement where module 72 ofFIG. 7A with four-heads is arranged in conjunction with module 62 ofFIG. 6B having two-heads. FIG. 7C depicts two equivalent modules 72 ofFIG. 7A arranged serially.

As is evident, in some arrangements shown, the same eight feed systems,feed components to various arrangements of heads and modules. As clearlydepicted, the modules are fairly modular and may generally bereconfigured or rearranged as may be necessary for a specific productassembly. As such, the embodiment shown in FIG. 6A may be arrangeddifferently but perform the same functionality of the embodiment shownin FIG. 3.

It can be seen that there are any number of possible permutations ofmodule, nozzle and head arrangements and that a user is thus free toselect and design, based on need, different arrangements for differentmachine throughput, capital, floor-space and system requirements andstill utilize the same basic physical operation. With such flexibility,scale-up and scale-down may occur more rapidly to maximize productionneeds. Thus, unlike the prior art, an arrangement for one productfamily, for instance the Gillette® Sensor® product family may betransferable or reconfigurable for use of manufacturing other productfamily or families, such as the Gillette® Venus®, Gillette® Mach3®, orGillette® Fusion® product families or vice-versa.

Nozzle operations may include contacting, picking, placing, holding,snap fitting, articulated inserting, angular inserting, cutting,assembling, clipping, crimping, staking, orienting (rotating, pivoting,swiveling, spinning, revolving, tilting, turning, aiming, twisting,pointing, inclining, rolling, or any combination thereof), transporting,dispensing, inspecting, identifying, cold heading, marking, stamping,printing, etching, force placement (e.g., pushing, moving, sliding) orother physical action or part movement, or any combination thereof, maybe performed by nozzle structures, some of which will be described belowin detail.

It should be noted that each nozzle may desirably be performing anoperation or combination of operations and as such, “paralleloperations” may be occurring.

Referring now to FIG. 8, a nozzle extends from head 82 a forming a novelnozzle structure 80 which includes a nozzle portion 82 having an outeror extension member 84 capable of contacting and/or operating on anexterior surface 87 of at least one razor component 86 in accordancewith an alternate preferred embodiment of the present invention. Outermember or adaptor 84 may desirably include an elongated portion as shownin FIG. 8 which may desirably be a rigid bar comprised of metal,plastic, urethane, rubber or any combination thereof. The adaptor 84 maythus be customized in shape and size for contacting a specific type ofcomponent. For instance, by being elongated, adaptor 84 may providebetter all-over support for an elongated razor component, such as ablade, a guard, or a lubricating strip. Depending on the cartridge orrazor component structure, adaptor 84, which acts as an adapter, may ormay not be necessary or a different type of adaptor may be required. Itshould be noted that any type of nozzle operation described herein maybe performed on the razor component 86 being held by the nozzle.

The adaptor 84 may also generally include any structure customized forcontacting the exterior surface of a razor component 86. For instance,adaptor 94 may include an angled portion 92, (e.g., or a taperedportion) customized for contacting the exterior surface 87 of a razorcomponent 86 such as the blade shown in nozzle structure 90 of FIG. 9.

In an alternate embodiment of the present invention, at least oneadaptor or adapter in the form of a gripper 104 having one or moregripper jaws 105 as shown in the nozzle structure 100 of FIG. 10 whichmay be actuated to move inward or outward (e.g., toward or away fromeach other) as indicated by arrows 110. The gripper jaws 105 may or maynot be identical and may be customized or modified over prior artgripper jaws to advantageously grasp surfaces of razor components whichotherwise may have been difficult to grasp or hard to balance (e.g.,elongated elements such as blades or lubricating strips, or clips). Thenozzle structure 100 may also generally include a vacuum means (notshown), magnetic, or other mechanical device for contacting cartridgecomponents.

Accordingly, the nozzle structure may include any customized adaptor,extension or outer member, for advantageously performing any operationon at least one razor cartridge component. Various adaptors contemplatedby the present invention are shown, though not exhaustively in FIG. 11.Generally, the adaptors are two or three dimensional, each dimensiondesirably ranging from about 10 mm to about 50 mm depending on the typeof adaptor. They are attached to the nozzles of current standard modulesvia any means, but generally mechanical means. The vacuum ability of thenozzle generally also remains unchanged or easily adjusted toaccommodate the type of adaptor. Additionally, these adaptors arebeneficial over those of the prior art in that they are easily removableor inter-changeable. Moreover, standard module machines are generallycapable of changing their own nozzles and thus accordingly, any attachedadaptors and also a head may also recognize and self-adapt for whatevertype of nozzle or adaptor is mounted thereon.

For instance, adaptor 114 a of FIG. 11 is shown to include a point ortriangulated outer structure which may aptly stake or assist in cuttingor slitting. Outer member or adapter 114 b has an angular base portionfor beneficial picking up of angled components such as razor blades orfor angular insertion. Adaptor 114 c is shown as having a wider anglethan that of adaptor 114 b, but also capable of similar operations.Adaptor 114 g is shown having a curved outer area 114 g′ also capable ofsimilar operation as adaptors 114 b and 114 c except with the addedbenefit of applicability to any curved components such as blades.Adaptor 114 d depicted as a rectangular rigid bar 115 with two base legs115 a may be capable of using legs 115 a as guides while at about centerof the rigid bar 115 a vacuum force from a nozzle or head providesstability.

Adaptor 114 e is depicted as having two rectangular shaped bars, oneupper 116 a and one lower bar 116 b, operatively coupled together viasprings 116 c allowing the lower bar flexibility when picking up oroperating on a component. This type of adaptor may be useful forcomponents that are generally more fragile, such as lubricating stripsor clips, or which may require a lighter force or have a lighter weight.

Adaptor 114 f is shown having a rounded end which may be aptly used forpushing in or inserting one component into another, e.g., a guard intohousing. Adaptor 114 h may desirably be used as a stamper, marker orprinter capable of placing text or graphics or other indicia on a razorcomponent. Adaptor 114 h may also be desirably capable of laser datecoding a component or finally formed cartridge. Adaptor 114 i is shownhaving two moveable legs 117 a which may turn towards each other or awayfrom each other. This arrangement may be desirably suitable for use witha large part or orienting or splitting one part into two.

The modules and equipment to assemble cartridges described herein mayalso be used in combination with non-pick/place equipment (e.g.,non-Printed Circuit Board, non-Electronic Component, ornon-Semiconductor Assembly equipment) or other prior art layouts. Forinstance, the modules described herein may incorporate equipment used inthe prior art such as described above in the Background of the Inventionsection with regard to custom designed tooling, gauging, and assemblyequipment.

In addition, the present invention contemplates the application of themodules described herein to the manufacture other types of consumerproduct areas and components thereof such as beauty care/cosmetic,medical and dental products, and powered versions thereof. For instance,in the beauty care/cosmetic area, a mirror compacts may be formed usingthe pick/place modules described herein where plastic, mirror, andpowder/liquid formulations components are assembled. Similarly, in thedental area, a toothbrush may be formed using a pick/place assemblymachine to assemble the various toothbrush components (e.g., head,handle, bristles). Customized modifications may be made to the outer oradaptors 84, 94, or 105 of the nozzle structures above to adequatelypick up a cosmetic component or a dental component.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A razor cartridge assembly apparatus comprising: a pick/placecomponent placement machine operating on at least one razor cartridgecomponent.
 2. The razor cartridge assembly apparatus of claim 1 whereinsaid pick/place component placement machine further comprises at leastone nozzle, said at least one nozzle adapted depending on a type of saidat least one razor cartridge component.
 3. The razor cartridge assemblyapparatus of claim 1 or 2 further comprising an adaptor comprising anelongated portion, an angled portion, a tapered portion, a gripperportion, a curved portion, a rounded portion, a pointed tip, a stamper,a marker, a printer, a guide portion, a spring portion, a moveable leg,or any combination thereof, for operating on said at least one razorcartridge component.
 4. The razor cartridge assembly apparatus of claim3 wherein said adaptor is comprised of metal, plastic, urethane, rubber,or any combination thereof.
 5. The razor cartridge assembly apparatus ofclaim 3 wherein said elongated portion comprises a rigid bar.
 6. Therazor cartridge assembly apparatus of claim 1 wherein at least onenozzle of said pick/place component placement machine performs at leastone operation comprising contacting, picking, placing, holding, snapfitting, articulated inserting, angular inserting, cutting, assembling,clipping, crimping, staking, orienting, transporting, dispensing,inspecting, identifying, cold heading, marking, stamping, printing(e.g., laser or ink), etching, force placement (e.g., pushing, moving,sliding) or other physical action or part movement, or any combinationthereof, at least one razor cartridge component, or at least oneexterior surface of at least one razor cartridge component and whereinsaid operation of orienting comprises rotating, pivoting, swiveling,spinning, revolving, tilting, turning, aiming, twisting, pointing,inclining, rolling, or any combination thereof.
 7. The razor cartridgeassembly apparatus of claim 6 wherein said at least one nozzle utilizesmechanical, electrical, chemical, magnetic, suction or vacuummechanisms, or any combination thereof.
 8. The razor cartridge assemblyapparatus of claim 1 wherein said at least one razor cartridge componentcomprises at least one cartridge housing, frame, or platform, at leastone razor blade, at least one cap, at least one guard, at least oneover-cap, at least one dispenser, at least one dispenser container, atleast one trimmer, at least one trimmer frame, at least one clip, atleast one lubricating strip or other chemistry, at least one cartridgeconnecting structure, or any combination thereof.
 9. The razor cartridgeassembly apparatus of claim 1 wherein said at least one razor cartridgecomponent is selected from a supply of at least one type of razorcartridge components disposed on at least one pallet.
 10. The razorcartridge assembly apparatus of claim 6 wherein said at least one nozzleis rotatable about at least one axis, said at least one axis comprisingan X axis, a Y axis, a Z axis, or any combination thereof.
 11. The razorcartridge assembly apparatus of claim 6 wherein said at least one nozzleis coupled to at least one head, said at least one head rotatable aboutat least one axis, said at least one axis comprising an X axis, a Yaxis, a Z axis, or any combination thereof.
 12. The razor cartridgeassembly apparatus of claim 1 further comprising a quality controlsystem to track said at least one razor cartridge component, to rejector repair a razor cartridge component, a partially assembled razorcartridge, a completed razor cartridge, or any combination thereof. 13.The razor cartridge assembly apparatus of claim 1 further comprising avision system adapted to facilitate at least one operation on said atleast one razor cartridge component, wherein said vision systemcomprises at least one camera wherein said at least one camera isconfigured to capture an image of said at least one razor cartridgecomponent, a partially assembled razor cartridge, a completed razorcartridge, or any combination thereof.
 14. (canceled)
 15. (canceled) 16.(canceled)
 17. (canceled)
 18. (canceled)
 19. An assembly apparatuscomprising: a pick/place component placement machine comprising at leastone nozzle adapted to operate on at least one consumer productcomponent.
 20. The assembly apparatus of claim 19 wherein said at leastone consumer product component is selected from a supply of at least onetype of consumer product components disposed on at least one pallet,wherein said at least one consumer product component comprises at leastone shaving product, medical product, dental product, or cosmeticproduct.
 21. The assembly apparatus of claim 19 wherein said at leastone nozzle performs at least one operation comprising contacting,picking, placing, holding, snap fitting, articulated inserting, angularinserting, cutting, assembling, clipping, crimping, staking, orienting,transporting, dispensing, inspecting, identifying, cold heading,marking, stamping, printing (e.g., laser or ink), etching, forceplacement (e.g., pushing, moving, sliding) or other physical action orpart movement, or any combination thereof, on said at least one consumerproduct component.
 22. The assembly apparatus of claim 19 wherein saidadapted nozzle further comprises an outer member comprising an elongatedportion, an angled portion, a tapered portion, a gripper portion, acurved portion, a rounded portion, a pointed tip, a stamper, a marker, aprinter, a guide portion, a spring portion, a moveable leg, or anycombination thereof, for operating on said at least one razor cartridgecomponent.